innovative routes for maximizing paraxylene production ... · bottom-of-the barrel conversion with...
TRANSCRIPT
1
Delphine Le-Bars
Maximizing Bottom-of-the Barrel
Conversion with Commercially Proven Technologies
Innovative Routes for Paraxylene Production
Christian Dupraz
2
1. Context
2. Solutions to Meet Increased Demand for Paraxylene
Increase Naphtha Production from Crude Oil
Implement New Breakthrough Technology Using
Alternate Low-cost Feedstock
Agenda
WRA - Egypt Downstream Summit, 2016
3
1. Context
2. Solutions to Meet Increased Demand for Paraxylene
Increase Naphtha Production from Crude Oil
Implement New Breakthrough Technology Using
Alternate Low-cost Feedstock
Agenda
WRA - Egypt Downstream Summit, 2016
4
Market Trend:
Maximize Heavy Naphtha Production from
crude oil
Increase in Aromatics
Production
+ 6.4% in PX Capacity
for 2014-2020
WRA - Egypt Downstream Summit, 2016
World Paraxylene Capacity, Production and Utilization Rate 2011-2020
PETROCHEMICALS
Implement new breakthrough technology using
alternate low-cost feedstock
5
1. Context
2. Solutions to Meet Increased Demand for Paraxylene
Increase Naphtha Production from Crude Oil
Implement New Breakthrough Technology Using
Alternate Low-cost Feedstock
Agenda
WRA - Egypt Downstream Summit, 2016
6
RFCC
HS-FCC
Bottom-of-the-Barrel Configuration Overview
AR
VR ARDS / VRDS
VGO
FCC Pretreat
Mild HCK
SDA EB Distillate
HCK
FCC
HS-FCC
HCK
VB
Delayed
Coker
Crude
Oil
Ebullated Bed Resid HCK
Slurry HCK
WRA - Egypt Downstream Summit, 2016
DHDT
CDU
GAS PLANT
Diesel
VDU
Bz / PX
C2= / C3= LPG
Light
Naphtha
Heavy
Naphtha
Jet
Diesel
Fuel
Oil
7
Reliability is key for
economics viability
How to Increase Naphtha Production?
Aromatic Complex
Residue
Conversion
Complex
Diesel
HDT
VGO
Hydrocracker
Naphtha
Middle Distillate
Kero
Diesel
UCO
Selection of Scheme/
Catalytic System for
Naphtha Maximization
Selection of a
Technology
Providing Maximum
Conversion and
Potential for HN
Production
Partial
Cracking of
Middle
Distillate Cut to
Naphtha
Selection of Light Crude
to Maximize Straight Run Naphtha A
DU
VD
U
VGO Atmospheric
Residue
Vacuum
Residue
Diesel
Fuel Oil
pX
Benzene
Middle
Distillate
VGO
Naphtha
Naphtha
Crude
Oil
WRA - Egypt Downstream Summit, 2016
PETROCHEMICALS
8
Vacuum Residue (VR) Feedstock
• Conversion into valuable products
› Naphtha, Diesel, VGO
• Unconverted Residue (UCO)
› Low Sulfur & Stable Fuel Oil
› Feed for Coker, SDA, Boilers or Gasification
Axens H-Oil®RC Residue HydroCracking Feedstock
WRA - Egypt Downstream Summit, 2016
High Value Products
UCO is a Liquid Fuel
Various Options for UCO Outlet
9
Axens H-Oil®RC Residue HydroCracking Principles
WRA - Egypt Downstream Summit, 2016
H2 + Feed
Catalyst Addition
Ebullated Bed
Ebullating Pump
Recycle Oil Catalyst Withdrawal
Robustness
Flexibility
Inter-stage
Separator
Ebullated-Bed Reactor
• Three-phase backmixed system
with Internal Liquid Recycle to
Expand Catalyst Bed
• Nearly Isothermal Reactor
• Low & Constant Pressure Drop
• Daily Addition/Withdrawal of
Catalyst
10
Superior Reliability
Avg. 96.6%
WRA - Egypt Downstream Summit, 2016
Availability of H-Oil® Units (2001-2010/2013)
11
H-Oil® & Solvent DeAsphalting Process (SDA) Combination
Combination of H-Oil® & Solvahl™ (SDA)
Option is to use SDA to eliminate remaining Asphaltenes
and further process DAO to increase conversion
Stability is the limiting factor due
to Asphaltenes condensation
0% 28% 48% 56% 74% 85%
With increased
conversion in Residue
HCK alone
540+ Conversion, wt%
WRA - Egypt Downstream Summit, 2016
12 WRA - Egypt Downstream Summit, 2016
H-Oil® Reactor
SolvahlTM
H-Oil® Reactor
Scheme Optimization
Tailored option to meet target depends on:
• Project Objective
• Products Requirement
• Feedstocks
• Site constraints
H-Oil® & Solvahl™ Combination Options
13
Conventional VR Feeds
› Middle East, Ural, etc.
Maximum Conversion
› Petrochemical application
› Middle Distillates production
H-Oil® & Solvahl™ Combination Example
UCO: Unconverted Oil
DAO: Deasphalted Oil
CFB: Circulating Fluidized Bed
Feedstock well suited for H-Oil®RC
High conversion in stand-alone H-Oil®RC
Up to 80 wt%
VR Conversion = 90wt%
WRA - Egypt Downstream Summit, 2016
14
How to Increase Naphtha Production?
Aromatic Complex
Residue
Conversion
Complex
Diesel
HDT
VGO
Hydrocracker
Naphtha
Middle Distillate
Kero
Diesel
UCO
Selection of Scheme/
Catalytic System for
Naphtha Maximization
Selection of a
Technology
Providing Maximum
Conversion and
Potential for HN
Production
Partial
Cracking of
Middle
Distillate Cut to
Naphtha
Selection of Light Crude
to Maximize Straight Run Naphtha A
DU
VD
U
VGO Atmospheric
Residue
Vacuum
Residue
Diesel
Fuel Oil
pX
Benzene
Middle
Distillate
VGO
Naphtha
Naphtha
Crude
Oil
WRA - Egypt Downstream Summit, 2016
PETROCHEMICALS
15
Two-Stage
Once-Through
HyKTM Hydrocracking Schemes - Flexibility
Main Product Yield
- Investment Cost +
Once-Through
With Recycle
Yield, wt%
HN ~ 30
MD 40-45
UCO 15
Yield,
wt%
With MD
Production
without
MD
Production
HN ~ 40 65-70
MD 40-45 -
UCO <1 <1
WRA - Egypt Downstream Summit, 2016
16
Maximization of Naphtha Production
Maximum Density Decrease and Cetane Improvement
through ring opening
Possibility of Upgrading Difficult Feedstocks such as
LCO from FCC and/or LCGO from Coker
Diesel Cut Hydrocracking
WRA - Egypt Downstream Summit, 2016
Catalyst Application
• High pressure
• High aromatic sat.
• Ring opening
• ULSD
• Maximum ∆ cetane/spgr
• Maximum volume swell
• Naphtha Production
NiMo
Cracking
Catalyst
17
1. Context
2. Solutions to Meet Increased Demand for Paraxylene
Increase Naphtha Production from Crude Oil
Implement New Breakthrough Technology Using
Alternate Low-cost Feedstock
Agenda
WRA - Egypt Downstream Summit, 2016
18
Aromatics Complex Historical Configuration
WRA - Egypt Downstream Summit, 2016
Aromatics Rings
Generation
NHT & Aromizing
Rings & Methyl Groups
Rearrangement
Transalkylation Loop
Xylenes Conversion to
Paraxylene
Xylenes Loop
PX
Naphtha
Aro
mati
cs
Fra
cti
on
ati
on
Secti
on
BZ
BZ + TOL
C9A+
C8A
C8A
19
EMTAM ParamaX® Complex Transalkylation Scheme Principles
Aromatics Rings
Generation
NHT & Aromizing
Toluene Methylation
EMTAM Loop
Xylenes Conversion to
Paraxylene
Xylenes Loop
PX
Naphtha
Aro
mati
cs
Fra
cti
on
ati
on
Secti
on
C8A
TOL
MeOH C8A
BZ & C9A+
Transalkylation C9A+ TOL
BZ
C8A
WRA - Egypt Downstream Summit, 2016
Naphtha consumption
reduced by 30%!
Transalkylation yields more
Toluene to EMTAM and more
C8A to Xylenes Loop
Larger PX rich C8A’s further
reduces Xylenes Loop
CAPEX & OPEX
20
EMTAM ParamaX® Complex Broader Picture Crude to PX Complex
Crude
VR Conversion
H-Oil®
SR & Cracked
GOs Conversion
Hydrocracking
SR & Cracked
Naphthas
Hydrotreatment
Aromatics
Rings
Generation
Aromizing Toluene
Methylation
EMTAM Loop
Xylenes
Conversion to
Paraxylene
Xylenes Loop
PX
Aro
ma
tic
s F
rac
tio
na
tio
n
Se
cti
on
C8A
TOL
MeOH
C8A
BZ & C9A+
Transalkylation C9A+ TOL
BZ
C8A
SRN
SR GO
SR VGO
VR H-Oil GO
HCK N
H-Oil N
WRA - Egypt Downstream Summit, 2016
Naphtha requirement
reduced by 30%!
21
Axens is offering a complete solution
for maximum production of Naphtha
for Aromatic Complex
• Solution with only proven and reliable
technologies
• High Stream Factor demonstrated
• Top Tier Catalysts for all applications
• Axens is the 1st Licensor to be awarded a
Full Integrated Scheme from VR to PX
New breakthrough technology to
enhance PX production
Conclusion
WRA - Egypt Downstream Summit, 2016